A brushless motor stator assembly for automobile cooling fan

Abstract

The invention discloses a brushless motor stator assembly for an automobile cooling fan, comprising a stator shell, a stator assembly and a PCBA assembly, wherein the stator assembly is embedded in the stator shell, the stator assembly comprises a stator core, a front insulating end cover and a rear insulating end cover arranged at the front and rear ends of the stator core, a stator winding is arranged between the front insulating end cover and the rear insulating end cover, three or six metal hooks are fixed on the rear insulating end cover, the stator winding is wound according to the winding rule and crosses the metal hooks and is clamped and welded to the metal hooks; a conductive bracket is fixed on the rear insulating end cover, a through hole is provided on the conductive bracket for conveniently passing the hooks, a PCBA board is detachably fixed at the rear end of the conductive bracket, a welding through hole is provided on the PCBA board, the metal hook passes through the welding through hole and is welded and electrically connected with the PCBA board. The stator winding of the motor stator assembly has higher winding efficiency, lower manual participation, and more regular winding.

Description

Technical Field

[0001] The invention relates to a stator assembly, in particular to a brushless motor stator assembly for an automobile cooling fan. Background Art

[0002] The stator assembly of the current brushless motor includes a stator shell, a stator assembly and a PCBA assembly, wherein the stator assembly is embedded in the stator shell, and the stator assembly includes a stator core, a front insulating end cover and a rear insulating end cover arranged at the front and rear ends of the stator core, and a stator winding is arranged between the front insulating end cover and the rear insulating end cover, and the current stator winding is generally a three-phase winding, which needs to be wound on the front insulating end cover and the rear insulating end cover by three enameled wires, and the ends of the three enameled wires are clamped and fixed together by three copper rings to achieve conductive connection, thereby achieving three-way connection, and then there is a connecting piece on the PCBA board, and the connecting piece and the copper ring are in contact and fixed by welding. However, the connection between the joint of the three-phase winding of this stator assembly and the PCBA board is very troublesome, and the copper ring needs to be put on the end, and then welded to the connecting piece of the PCBA board. In order to ensure that there is no cold soldering, the contact between the connecting piece and the copper ring and the installation of the copper ring require manual participation, which is very inefficient and also makes the stator assembly have more wire ends and more confusion. Summary of the invention

[0003] The technical problem to be solved by the present invention is to provide a brushless motor stator assembly for an automobile cooling fan, wherein the stator winding of the motor stator assembly has higher winding efficiency, lower manual participation, and more regular winding.

[0004] In order to solve the above technical problems, the technical solution of the present invention is: a brushless motor stator assembly for an automobile cooling fan, comprising a stator shell, a stator component and a PCBA component, wherein the stator component is embedded in the stator shell, the stator component comprises a stator core, a front insulating end cover and a rear insulating end cover arranged at the front and rear ends of the stator core, a stator winding is arranged between the front insulating end cover and the rear insulating end cover, three or six metal hooks are fixed on the rear insulating end cover, the stator winding is wound according to the winding rule and crosses the metal hook and is clamped and welded to it, so that the stator winding forms a three-phase winding; a conductive bracket is fixed on the rear insulating end cover, the conductive bracket is provided with a through hole for conveniently passing the hook, a PCBA board is detachably fixed at the rear end of the conductive bracket, a welding through hole is provided on the PCBA board, the metal hook passes through the welding through hole and is welded and electrically connected with the PCBA board.

[0005] As a preferred solution, the metal protective hook includes a protective hook body, the front end of the protective hook body is inserted and fixed with the rear insulating end cover, and the outer side of the protective hook body is provided with a hook portion for convenient winding.

[0006] As a preferred solution, the protective hook body is a plate-like structure, the front end of the protective hook body is opened with two strip-like openings extending forward and backward, the plate portion between the strip-like openings is bent outward to form the hook portion, inverted tooth structures are provided on both sides of the front end of the protective hook body, and the surface of the rear insulating end cover is provided with an embedding groove.

[0007] As a preferred solution, a plurality of bolt mounting parts are provided on the rear insulating end cover, and the PCBA board is fixed to the bolt mounting parts by grounding bolts. A grounding spring is provided on the grounding bolt, and the grounding bolt connects the grounding spring to the grounding electrode on the PCBA board.

[0008] As a preferred solution, the fixing method between the rear insulating end cover and the conductive bracket is a clip-on fixation, and a plurality of hooks are provided on the rear insulating end cover, and a hook portion extending outward is provided at the rear end of the hook, and a hook step cooperating with the hook portion is provided on the conductive bracket.

[0009] As a preferred solution, a centralized wiring area is provided on the back of the PCBA board, a wiring bracket is provided on the centralized wiring area, and a plurality of conductive pins on the wiring bracket are welded and fixed to the PCBA board.

[0010] As a preferred solution, when there are three metal hooks, the stator winding is wound according to the winding rules and crosses the metal hooks to be clamped and welded to them. When clamping and welding, the enameled wire of the stator winding is broken and connected to the three metal hooks by clamping and welding to form a three-phase winding;

[0011] When there are six metal guard hooks, the metal guard hooks are divided into three groups in pairs, wherein the stator winding is wound according to the winding rule and crosses the metal guard hooks to be clamped and welded to them, and the two metal guard hooks of the first group are conductively connected by enameled wire welding, and two conductive connecting pieces are embedded in the conductive bracket, and each conductive connecting piece is provided with two connecting pins, wherein the two connecting pins of one conductive connecting piece are conductively connected to the two metal guard hooks of the second group one by one, and the two connecting pins of the other conductive connecting piece are conductively connected to the two metal guard hooks of the third group one by one, and the three groups of metal guard hooks pass through the welding through holes and are electrically connected to the PCBA board by welding to form a three-phase winding of the stator winding.

[0012] After adopting the above technical scheme, the effect of the present invention is as follows: since three or six metal hooks are fixed on the rear insulating end cover, the stator winding is wound according to the winding rule and crosses the metal hooks and is clamped and welded to the stator winding, so that the stator winding forms a three-phase winding; a conductive bracket is fixed on the rear insulating end cover, and a through hole is provided on the conductive bracket for convenient passage of the hook, and a PCBA board is detachably fixed at the rear end of the conductive bracket, and a welding through hole is provided on the PCBA board, and the metal hook passes through the welding through hole and is welded and electrically connected with the PCBA board, so that the stator winding crosses the metal hook when winding, and the metal hook can clamp the winding, and then the winding will be broken when clamping and welding, so that the welding conductive connection of the corresponding end is completed, thereby realizing the three-phase winding, and the winding of the entire stator assembly is more convenient and neater. At the same time, there is no need to use copper rings, which saves manpower, and the winding can be directly wound and then automatically clamped and welded, which is more efficient, and the metal hook is directly inserted into the welding through hole of the PCBA board, which is convenient for the welding conductive connection of the PCBA board.

[0013] Since the protective hook body is a plate-like structure, the front end of the protective hook body is provided with two strip-like openings extending forward and backward, the plate portion between the strip-like openings is bent outward to form the hook portion, the front ends of the protective hook body are provided with inverted tooth structures, and the surface of the rear insulating end cover is provided with an embedding groove. The protective hook body is easy to shape and is firmly fixed to the rear insulating end cover.

[0014] Furthermore, since a plurality of bolt mounting parts are provided on the rear insulating end cover, the PCBA board is fixed on the bolt mounting part through a grounding bolt, and a grounding spring is provided on the grounding bolt. The grounding bolt connects the grounding spring to the grounding electrode on the PCBA board, and the grounding spring is directly fixed on the grounding bolt, so the grounding is also very firm.

[0015] Furthermore, since the fixing method between the rear insulating end cover and the conductive bracket is a clip-on fixation, a plurality of clip hooks are provided on the rear insulating end cover, a hook portion extending outward is provided at the rear end of the clip hook, and a hook step cooperating with the hook portion is provided on the conductive bracket, the rear insulating end cover can be fixed to the conductive bracket very well.

[0016] Furthermore, since a centralized wiring area is provided on the back of the PCBA board, a wiring bracket is provided on the centralized wiring area, and a plurality of conductive pins on the wiring bracket are welded and fixed to the PCBA board, the conductive pins can be well integrated by using the wiring bracket, which makes it more convenient to connect the PCBA board with external wires. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0018] Figure 1is a three-dimensional structural diagram of embodiment 1 of the present invention;

[0019] Figure 2 is an exploded schematic diagram of a stator assembly according to Embodiment 1 of the present invention;

[0020] Figure 3 is an exploded schematic diagram of a stator assembly according to Embodiment 1 of the present invention;

[0021] Figure 4 yes Figure 2 An enlarged schematic diagram at A;

[0022] Figure 5 It is a three-dimensional picture of the metal guard hook;

[0023] Figure 6 is an exploded schematic diagram of a stator assembly according to Embodiment 2 of the present invention;

[0024] Figure 7 is a winding schematic diagram of embodiment 2;

[0025] In the attached figure: 1. stator housing; 2. PCBA board; 21. wiring bracket; 22. conductive pin; 23. grounding spring; 3. stator core; 4. front insulating end cover; 5. rear insulating end cover; 51. hook; 52. embedded groove; 6. conductive bracket; 61. bolt mounting part; 62. hooking step; 63. connecting pin one; 64. connecting pin two; 7. metal protective hook; 71. strip opening; 72. hook; 73. inverted tooth structure; 8. stator winding. DETAILED DESCRIPTION

[0026] The present invention is further described in detail below through specific examples.

[0027] The front mentioned in the present invention means that the end of the brushless motor rotor shaft extending out is the front, and the corresponding side is the rear.

[0028] Example 1

[0029] like Figures 1 to 5 As shown, a brushless motor stator assembly for an automobile cooling fan includes a stator shell 1, a stator component and a PCBA component. The stator component is embedded in the stator shell 1. The stator component includes a stator core 3, a front insulating end cover 4 and a rear insulating end cover 5 arranged at the front and rear ends of the stator core 3. The front insulating end cover 4 and the rear insulating end cover 5 are both embedded and arranged at the front and rear ends of the stator core 3, and can be fastened by winding.

[0030] A stator winding 8 is arranged between the front insulating end cover 4 and the rear insulating end cover 5, and three metal hooks 7 are fixed on the rear insulating end cover 5. The stator winding 8 is wound according to the winding rule and crosses the metal hooks 7 to be clamped and welded to the stator winding 8, so that the stator winding 8 forms a three-phase winding; when there are three metal hooks 7, the stator winding 8 is wound according to the winding rule and crosses the metal hooks 7 to be clamped and welded to the metal hooks 7, and the enameled wire of the stator winding 8 is broken and conductively connected with the three metal hooks 7 by clamping and welding during clamping and welding to form a three-phase winding; this winding method is the conventional winding method of the current motor, except that during the winding process, the enameled wire will cross the metal hooks 7, so that a conductive connection is formed during clamping and welding, thereby realizing a three-phase winding.

[0031] A conductive bracket 6 is fixed on the rear insulating end cover 5, and a through hole is provided on the conductive bracket 6 for the protective hook to pass through. The rear end of the conductive bracket 6 is detachably fixed with a PCBA board 2, and a welding through hole is provided on the PCBA board 2. The metal protective hook 7 passes through the welding through hole and is welded and electrically connected with the PCBA board 2.

[0032] The metal hook 7 includes a hook body, the front end of which is fixedly inserted with the rear insulating end cover 5, and a hook portion 72 for convenient winding is arranged on the outside of the hook body. The hook body is a plate-like structure, and the front end of the hook body is provided with two strip-shaped openings 72 extending forward and backward. The plate portion between the strip-shaped openings 72 is bent outward to form the hook portion 72. The front ends of the hook body are provided with inverted tooth structures 73, and the surface of the rear insulating end cover 5 is provided with an embedding groove 52.

[0033] In such Figures 2 to 5 The rear insulating end cover 5 is provided with a plurality of bolt mounting portions 61 , and the PCBA board 2 is fixed to the bolt mounting portions 61 by means of grounding bolts, and a grounding spring 23 is provided on the grounding bolt, and the grounding bolt connects the grounding spring 23 to the grounding electrode on the PCBA board 2 .

[0034] The rear insulating end cover 5 and the conductive bracket 6 are fixed by clamping. The rear insulating end cover 5 is provided with a plurality of hooks 51, and the rear end of the hook 51 is provided with a hook portion 72 extending outward, and the conductive bracket 6 is provided with a hooking step 62 that is hooked with the hook portion 72. The back of the PCBA board 2 is provided with a centralized wiring area, and the centralized wiring area is provided with a wiring bracket 21. The plurality of conductive pins 22 on the wiring bracket 21 are fixed to the PCBA board 2 by welding.

[0035] Example 2

[0036] like Figure 6 and Figure 7As shown, the number of the metal guard hooks 7 in this embodiment is six, and the metal guard hooks 7 are divided into three groups in pairs. Figure 7 It can be found that the three groups of metal hooks 7 are: V1-V2; W1-W2; U1-U2, a total of three groups, wherein the stator winding 8 is wound according to the winding rule and crosses the metal hooks 7 and is clamped and welded to it, and the two metal hooks 7 of the first group are conductively connected by enameled wire welding, and the conductive bracket 6 is embedded with two conductive connecting pieces, each of which is provided with two connecting pins, namely two connecting pins 1 63 and two connecting pins 2 64, wherein the two connecting pins 1 63 of one conductive connecting piece are conductively connected to the two metal hooks 7 of the second group one by one, and the two connecting pins 2 64 of another conductive connecting piece are conductively connected to the two metal hooks 7 of the third group one by one, and the three groups of metal hooks 7 pass through the welding through holes and are welded and electrically connected to the PCBA board 2 to form a three-phase winding of the stator winding 8.

[0037] like Figure 7 As shown, Figure 7 There are 12 winding slots in the stator core 3, which are defined as slots 1-12 respectively, wherein the winding route of the enameled wire is: V1-1 slot-4 slot-W1-2 slot-5 slot-U1-3 slot-6 slot-V2-7 slot-10 slot-W2-8 slot-11 slot-U2-9 slot-12 slot-V1-V2, wherein V1 and V2 are connected by another wire, and W1 and W2, U1 and U2 are connected by conductive connecting pieces in the conductive bracket 6 respectively.

[0038] The above-described embodiments are merely descriptions of preferred implementations of the present invention and are not intended to limit the scope of the present invention. Various modifications and alterations to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the scope of protection defined by the claims of the present invention.

Claims

1. A brushless motor stator assembly for an automobile cooling fan, comprising a stator housing, a stator assembly and a PCBA assembly, wherein the stator assembly is embedded in the stator housing, and characterized in that: The stator assembly includes a stator core, a front insulating end cover and a rear insulating end cover arranged at the front and rear ends of the stator core, a stator winding is arranged between the front insulating end cover and the rear insulating end cover, six metal hooks are fixed on the rear insulating end cover, the stator winding is wound according to the winding rule and crosses the metal hooks and is clamped and welded to them, so that the stator winding forms a three-phase winding; a conductive bracket is fixed on the rear insulating end cover, the conductive bracket is provided with a through hole for the metal hook to pass through, a PCBA board is detachably fixed to the rear end of the conductive bracket, a welding through hole is provided on the PCBA board, the metal hook passes through the welding through hole and is welded and electrically connected to the PCBA board; the six metal hooks are divided into three groups in pairs, and the two metal hooks in the first group are conductively connected by enameled wire welding, and two conductive connecting holes are embedded in the conductive bracket The connecting piece, each conductive connecting piece is provided with two connecting pins, wherein the two connecting pins of one conductive connecting piece are respectively and electrically connected with the two metal hooks of the second group in a one-to-one correspondence, and the two connecting pins of the other conductive connecting piece are respectively and electrically connected with the two metal hooks of the third group in a one-to-one correspondence, and the three groups of metal hooks pass through the welding through holes and are welded and electrically connected with the PCBA board to form a three-phase winding of the stator winding; the metal hook comprises a hook body, the front end of the hook body is fixedly inserted with the rear insulating end cover, and the outer side of the hook body is provided with a hook portion for winding; the hook body is a plate-like structure, the front end of the hook body is opened to have two strip-like openings extending forward and backward, the plate portion between the strip-like openings is bent outward to form the hook portion, the front ends of the hook body are provided with inverted tooth structures, and the surface of the rear insulating end cover is provided with an embedding groove.

2. A brushless motor stator assembly for an automobile cooling fan as claimed in claim 1, characterized in that: The rear insulating end cover is provided with a plurality of bolt mounting parts, the PCBA board is fixed on the bolt mounting parts by grounding bolts, the grounding bolts are provided with grounding springs, and the grounding bolts connect the grounding springs with the grounding electrodes on the PCBA board.

3. A brushless motor stator assembly for an automobile cooling fan as claimed in claim 2, characterized in that: The rear insulating end cover and the conductive bracket are fixed by clipping. The rear insulating end cover is provided with a plurality of clip hooks, and the rear end of the clip hook is provided with a hook portion extending outward, and the conductive bracket is provided with a hook step that cooperates with the hook portion.

4. A brushless motor stator assembly for an automobile cooling fan as claimed in claim 3, characterized in that: A centralized wiring area is arranged on the back of the PCBA board, a wiring bracket is arranged on the centralized wiring area, and a plurality of conductive pins on the wiring bracket are welded and fixed to the PCBA board.

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